Sanding apparatus and method of manufacture

ABSTRACT

An improved resilient sanding block of the type comprising a core having a plurality of exterior surfaces, including a first major surface and a second major surface and side surfaces, and having a layer of abrasive material disposed thereon. The resilient sanding block may have one or more apertures or through holes extending from one major surface to the other major surface and channels formed in at least one of the major surfaces, with the channels in communication with the aperture. When a vacuum source is operatively connected to the aperture, the dust created by sanding will be substantially removed into the vacuum source via the channels and the aperture. A holder for a resilient sanding block is also disclosed, as well as a handle for the holder, which together form a sanding system.

This application claims benefit to a provisional application No.60/657,461 filed on Mar. 1, 2005 which is hereby incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to surface finishing tools.Particularly, the present invention relates to flexible sanding tools.More particularly, the present invention relates to resilient sandingblocks that can be used in conjunction with a holder to improve theuser's grip and which can be used in conjunction with components ofexisting surface finishers to form a dustless sanding system.

2. Description of the Related Art

Dustless sanding tools and dustless sanding have been known andpracticed in the construction trades for a number of years. Knowndustless sanding tools comprise a handle that connects to a vacuumsource, and a sanding element, such as a sanding screen, which attachesto the bottom surface of the tool by means of clamping mechanisms. Suchbottom surfaces are provided with through holes or grooves that are incommunication with the vacuum source, and over which the sanding screenis positioned. In operation, dust is sucked through apertures in thescreen and the grooves or through holes and is deposited into acollection receptacle.

Such dustless sanding tools have many disadvantages. They are not usefulfor small jobs, or jobs that have a limited amount of space in which tooperate. They are not economical, especially for small jobs, because theuser must purchase a hand held tool as well as an abrasive sandingscreen, which are not inexpensive. Additionally, existing dustlesssanding tools are designed to work only in a reciprocating motion andoften, the suction force developed by the vacuum causes the sander to beclamped to the surface being sanded. Another drawback is that the bottomsurface is made from relatively rigid material such as plastic or hardrubber. This makes it difficult, if not impossible, to sand a curved orundulating surface. Further, the hard bottom commonly leaves relativelydeep grooves in drywall that requires subsequent re-finishing. Moreover,these known dustless sanding tools are large, heavy and cumbersome.

There is a need for a sanding tool that has the abrasive materialincorporated into the tool itself, rather than requiring an abrasivematerial be attached to a tool. There is a need for a sanding tool madeof a resilient material so the tool that is able to conform to irregularsurfaces. There is a need for a sanding tool that is inexpensive tomanufacture and disposable. There is a need for a compact andlightweight dustless sanding tool. There is a need for a resilientsanding block that can be used with existing dustless sandingcomponents. And, there is a need for a small, portable, dustless sandingsystem that can be easily transported about a job site.

SUMMARY OF THE INVENTION

It is an object of the present invention to increase the utility ofknown sanding tools that may be optionally connected to a-vacuum device.The present invention achieves this objective by providing an existingresilient sanding block having a centrally located through hole oraperture and one or more channels located and formed on sanding surfacesof the block. The aperture may be directly connected to a vacuum sourceor it may be attached to a holder that directs a vacuum source to thesanding surface of the resilient sanding block. The block may be morethan one aperture or through holes depending on the particular type ofholder that will be used in conjunction with the block.

More specifically, the resilient sanding block has a plurality ofsurfaces including a first and second major surface. Abrasive materialmay be disposed on one or both of the major surfaces. The channels onthe major surfaces may be formed in a variety of patterns and aregenerally in communication with the aperture. When a suction force isapplied to the aperture, dirt and dust will travel through the channelsand then up through the aperture. From there, the dirt and dust will bedirected towards the vacuum source and into a collection receptacle. Ifthe resilient block is attached to a holder, the dirt and dust willtravel from the channel, through the aperture and into the holder, whichwill direct the debris toward the vacuum source and into the collectionreceptacle.

A resilient sanding block of the present invention may be manufacturedby taking an existing block with an abrasive material disposed on atleast one major surface and forming at least one through hole oraperture between the major surfaces of the block. Channels may then beformed to be in communication with the aperture(s). The resilientsanding block of the present invention may also be manufactured by firstforming channels in the major surfaces of the block and then forming athough hole between the major surfaces of the block.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the resilient sandingblock of the present invention showing a first major material workingsurface;

FIG. 2 is side elevational view of the embodiment of FIG. 1;

FIG. 3 is an inverted perspective view of the resilient sanding block ofFIG. 1 showing a second major material working surface;

FIG. 4 is a perspective view of another embodiment of the resilientsanding block of the present invention;

FIG. 5 is a partial side elevational, partial cross-sectional view ofresilient sanding block of FIG. 4;

FIG. 6 is an overhead perspective view of one embodiment of a sandingsystem comprising a resilient sanding block of the present invention inassociation with a holder;

FIG. 7 is a cross-sectional, side elevational view of the sanding systemof FIG. 6;

FIG. 8 is a cross-sectional view of another embodiment of a sandingsystem comprising a resilient sanding block of the present invention inassociation with an alternatively configured holder;

FIG. 9 is a top plan view of the embodiment of FIG. 8;

FIG. 10 a is a cross-sectional, side elevational view of anotherembodiment of a sanding system that is similar to the sanding system asshown in FIG. 8;

FIG. 10 b is a side elevational, cross-sectional, split view ofalternative methods for attaching a resilient sanding block to a holder;

FIG. 11 is a partial bottom plan view of the sanding system of FIG. 10 ashowing portion resilient sanding block in conjunction with the holderof FIG. 10 a;

FIG. 12 is an overhead perspective view of an embodiment of a holder ofthe present invention;

FIG. 13 is a cross-sectional view of the holder of FIG. 12;

FIG. 14 is an inverted, overhead, perspective, cut-away view of theholder of FIGS. 12 and 13;

FIG. 15 is an exploded perspective view of a sanding system comprising aresilient sanding block, the holder of FIGS. 12-14, and a handle;

FIG. 16 is an overhead perspective view of another embodiment of asanding system that is configured to be used with a job-specificresilient sanding block;

FIG. 17 is a side elevational, cross-sectional view of the sandingsystem of FIG. 16;

FIG. 18 is a cross-sectional bottom plan view of the sanding system ofFIG. 16;

FIG. 19 is an overhead, perspective view of alternative embodiment of asanding system comprising a resilient sanding block and a holder thatfunctions as a handle;

FIG. 20 is a side elevational, cross-sectional view of the sandingsystem of FIG. 19;

FIG. 21 is a bottom, cross-sectional plan view of the sanding system ofFIG. 19;

FIG. 22 is an exploded perspective view of another embodiment of asanding system of the present invention in which an abrasive sheet isattached to a resilient block, and the resilient block us receivedwithin a reinforced holder;

FIG. 23 is side elevational view of an embodiment of a machine used tomanufacture the resilient sanding block of the present invention;

FIG. 24 is a partial, side elevational end view of the machine of inFIG. 23; and

FIG. 25 is a partial top view of the machine of FIG. 23 with the upperblades removed for clarity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is illustrated in FIGS. 1-25. FIG. 1 shows aperspective view and FIG. 2 shows and end view of the preferredembodiment of the present invention. Generally, the resilient sandingblock 10 comprises a core 12, major surfaces 24, 26, side surfaces 16,20, and end surfaces 18, 22. More specifically, a first major surface 24is best shown in FIG. 1 and the second major surface 26 is best shown inFIG. 3. The resilient sanding block 10 comprises a core 12 havingprimary channels 42 a, 44 a, 44 b, 46 a, 48 a, 48 b, 50 a, 52 a, 52 b,54 a, 56 a, and 56 b that are in communication with an aperture 80. Thecore 12 further comprises secondary channels 60 a, 60 b, 62 a, 62 b, 64a, 64 b, 66 a, 66 b, 68 a, 68 b, 70 a, 70 b, 72 a, 72 b, 74 a, and 74 bthat are in communication with the primary channels 42-56. The core 12is made of a resilient material, preferably polyurethane foam, foamrubber or sponge. However, it will be understood that other materialshaving similar properties may be used without departing from the spiritand scope of the invention. Preferably, the resilient sanding block 10has have a height of about 1 to about 5 cm, more preferably about 2 toabout 3 cm. In this embodiment, the resilient sanding block 10 has twolayers of abrasive material 30 a, 30 b disposed on its first and secondmajor surfaces 24, 26, respectively.

In this present embodiment, an aperture or through hole 80 is formed inthe resilient sanding block 10 so that it extends through the thicknessof the core 12 from the first major surface 24 to the second majorsurface 26. Preferably, the aperture 80 is generally located in thecenter of the resilient sanding block 10. Preferably, the primarychannels 42-56 (see also FIG. 3) are in communication with the aperture80. A vacuum source (not shown) is operatively connected to the aperture80 by means of a vacuum hose (not shown) having a nozzle or end that maybe inserted into the aperture 80. As will be understood, when the firstor second major surface is in contact with a working surface, theworking surface substantially covers the channels so as to formtemporary conduits. It will be further understood that the vacuum forcewill be transferred into the temporary conduits. A vacuum force can alsobe directed to the aperture 80 by use of a holder (see, for example,FIG. 5) or by attachment of the vacuum source (not shown) directly tothe aperture 80.

The channels 42-74 can be formed, molded or cut into the core 12 and arerecessed just below the first major surface 24 or the second majorsurface 26 of the core 12 to allow air to be sucked into the channels42-74 from outside the core 12 and into the aperture 80. As betterillustrated in FIG. 8, air, bringing the dust with it, then travelsthrough the holder 202 and into the vacuum attachment 340 and then intoa collection receptacle of a vacuum source (not shown).

Referring particularly now to FIG. 1, in this embodiment, the channels42-74 form a pattern or grid. The secondary channels 60-74 outline theresilient block 10 while the primary channels 42-56 extend in a radialpattern from the aperture 80. In this embodiment, the channel patternallows all channels 42-74 to be interconnected with each other and withthe aperture 80 thereby distributing the vacuum force to all thechannels 42-74. Although the arrangement of channels 42-74 describedhere is the preferred embodiment, the invention should not be limited tothis channel configuration but could include any channel configurationor pattern that serves the purpose of collecting dust while abrading asurface and is similar in concept. Moreover, the particularconfiguration of the sanding block need not be limited to a rectangularshape. For example, the resilient sanding block could be circular ortriangular. In such cases, it will be understood that the channels willbe appropriately configured.

As seen in FIG. 3, a channel pattern can be made with fewer channelsthan the number of channels in the first major surface 24 as shown inFIG. 1, thereby providing more abrasive material 30 b on the secondmajor surface 26, without sacrificing the efficiency of the dustchanneling capability of the resilient sanding block 10. Although notshown, the channel pattern can consist of any number of channelsconsisting of vertical, horizontal, diagonal or even curved or nonlinearchannels that are formed in the major surfaces.

The channels should not be limited in shape and can have any number ofcross-sectional profiles including a “v”-shaped groove, round or flatbottom, square or rectangular. A square or rectangular shaped channel ispreferred. More preferably, the channels will have a depth and width ofabout 0.5 to about 7.0 mm, more preferably 1.0 to about 5.0 mm. It ispreferred, although not necessary, that the resilient sanding block beprovided with channels in the first major surface 24, as well as thesecond major surface 24, 26 so that resilient sanding block may beinverted and the first and second major surface 26. Additionally, it ispreferred that the apertures have a diameter that is larger than thecross-sectional area of the channels.

The resilient sanding block 10 should also not be limited in the numberof surfaces that are coated with abrasive material. For example, thefirst major surface 24, the second major surface 26, two end surfaces18, 22, and the side surfaces can be coated with abrasive material and apattern of channels can be applied to only the first major surface 24.It should be noted that any combination of sides with or withoutabrasive coating or with or without channels can be included in thescope of the invention and the present invention should not be limitedin scope by leaving out any combination. Moreover, it is envisioned thatthe surfaces of the resilient sanding block may be provided withdifferent grades of abrasive material.

FIGS. 4 and 5 depict another embodiment of the present invention,similar to that shown in FIGS. 1-3. Generally, the resilient sandingblock 110 comprises a core 112, major surfaces 124, 126, side surfaces116, 120, and end surfaces 118, 122. In this embodiment, the resilientblock 110 has two apertures 180 a and 180 b. Similarly, the resilientsanding block 110 comprises a core 112 having primary channels 142 a,142 b (not shown), 144 a, 144 b, 146 a, 146 b, 148 a, 148 b, 150 a, 150b (not shown), 152 a, 152 b, 154 a, 154 b (not shown), 156 a, and 156 bthat are in communication with an aperture 180 a. The core 112 furthercomprises secondary channels 160 a, 160 b, 162 a, 162 b, 164 a, 164 b,166 a, 166 b, 168 a, 168 b, 170 a, 170 b (not shown), 172 a, 172 b (notshown), 174 a, and 174 b (not shown) that are in communication with theprimary channels 142 a, 142 b, 144 a, 144 b, 146 a, 146 b, 148 a, 148 b,152 a, 152 b, 154 a, 154 b, 156 a, and 156 b. Additionally, the core 112has primary channels 142 c, 142 d, 144 c, 144 d, 146 c, 146 d (notshown), 148 c, 148 d (not shown), 150 c, 150 d (not shown), 152 c, 152d, 154 c, 154 d, 156 c, and 156 d that are in communication with anaperture 180 b and secondary channels 160 c, 160 d, 162 c, 162 d (notshown), 164 c, 164 d, 166 c, 166 d, 168 c, 168 d, 170 c, 170 d, 172 c,172 d, 174 c, and 174 d that are in communication with the primarychannels 142 c, 142 d, 144 c, 144 d, 146 c, 146 d (not shown), 148 c,148 d, 150 c, 150 d (not shown), 152 c, 152 d, 154 c, 154 d, 156 c, and156 d. Again, the channels are operatively connected to correspondingapertures in a manner similar to the channels shown and described inFIG. 1. Note, however, that some of the channels are in communicationwith more than one aperture.

FIGS. 6 and 7 depict a sanding system 200, which is formed by a holder202 that connects a vacuum source (not shown) and a resilient sandingblock 210. The holder 202 further comprises a shell 204 into which aresilient sanding block 210 can be substantially inserted andfrictionally retained. The shell 204 has an aperture 207 that allows airto pass from the resilient sanding block 210 via channels and anaperture 280 to a passageway 206 when a vacuum source (not shown) isoperatively connected to the sanding system 200 through a vacuumattachment 240 tube. The holder 202 may be of the type presently usedwith sanding tools.

FIGS. 8 and 9 show an alternate embodiment of a sanding system 300comprising a holder 302 that connects to a vacuum source (not shown) anda resilient sanding block 310. Here, the holder 302 comprises apassageway 306 defined by a holder 302 that is attached to a triangularplate 244 having a flange 346 a with block grippers or teeth 348 a thatare angled with respect to the flange 346 a. A tube 308 is connected tothe end of the plate 344. An aperture 307 in the plate 344 allows air toflow between the passageway 306 into the tube 308. The tube 308 isinserted into aperture 380 of the resilient sanding block 310, whichallows air to be drawn through channels on the first major surface 324of the resilient sanding block 310 into the tube 308, through thepassageway 306 and into the vacuum source 340.

FIGS. 10 a, 10 b, and 11 depict alternate embodiments of a holder for aresilient sanding block. Here, the holder 302 comprises a plate 344 thathas two downwardly extending flanges 346 a-b and two sets of teeth 348a-b that extend towards each other in a direction that is generallyparallel to the plate 344, and, which serve as a means to retain theresilient sanding block 310 in close proximity to the plate 344.Additionally, an optional handle 342 (not shown in FIG. 11) is attachedto the plate 344 to provide a better grip for the user. A tube 308 isattached to the holder 302 and extends down from an aperture 307 in theplate 344 and into an aperture 380 in the block 310, with the aperture380 in communication with channels as previously described. Note thatthe sanding block 310 does not have channels on both major surfaces.

FIG. 10 b depicts alternative means for retaining a resilient sandingblock in close proximity to the plate 344 of a holder 302. As can beseen on the left side of the figure, hook 346 a′ and loop fasteners 346a″ may be used. Whereas, on the right side of the figure, adhesives 346b may be used.

FIGS. 12-15 show an alternate embodiment of a sanding system 400comprising a holder 402, a resilient sanding block 410, and a handle442. The holder 402 comprises a first shell 404 a and a second shell 404b. The first shell 404 a comprises a top wall 405 a and side walls 407 aextending downwardly therefrom, and is configured to frictionally retaina resilient sanding block 410. Note that the side walls 407 a havewedge-shaped teeth 448 a-b as to provide a firm grip on the block 410.The second shell 404 b comprises a top wall 405 b, a set of side walls407 b, and two collars 446. The first shell 404 a is configured andarranged to substantially reside within the second shell 404 b in agenerally nesting relation, and with the first shell 404 a connected tothe second shell 404 b such that a passageway 406 is formed between thewalls of the first and second shells 405 a-b, 407 a-b. Preferably, thefirst and second shells 404 a-b are connected to each other by one ormore spacers or ribs 450. The passageway 406 allows air/dust to be drawnfrom around the periphery of the resilient sanding block 410 and to adust collection receptacle (not shown). As shown, the second shell 404 bis provided with two collars 446 that line up with the apertures 452 ina handle 442. The collars 446 extend the passageway 406 so that air anddust can flow between the second shell 404 b and the first shell 404 aand then ultimately out of the sanding device 400 through the vacuumattachment 438 and in to a collection receptacle (not shown). Thecollars 446 may be fitted to apertures 452 in the base of the handle 442to operatively connect the holder 402 to the handle 442. The handle 442may be of known types presently used in sanding tools and may beattached to the holder 402 with fasteners 444.

FIGS. 16-18 show an alternate embodiment of a sanding system 500comprising a holder 502 attached to a resilient sanding block 510 havinga similar shape and angle as an angled sanding apparatus commonly usedfor sanding drywall corners. Generally, this system 500 is similar tothe previously described system of FIGS. 12-15 in that it comprises aholder 502 having a first shell 504 a and a second shell 504 b. Apassageway 506 is formed between the first shell 504 a and the secondshell 504 b that allows for air/dust to be drawn from around theperiphery of the resilient sanding block 510 to a dust collectionreceptacle (not shown) via a vacuum attachment 540. The first shell 504a frictionally retains the resilient sanding block 510. A passageway 506is formed between the first and second shells 504 a, 504 b to facilitateair flow from around the resilient sanding block 510 into the passageway506 and then into the vacuum attachment 538 and out of the sandingsystem 500. Preferably, the shells 504 a-b are connected to one anotherwith spacers or ribs 550 that are positioned at intervals to provide forair to flow between the shells 504 a-b.

This system 500 differs, however, in that it is designed to work inconjunction with irregularly, job specific angled sanding blocks 510. Tothat end, the walls of the second shell 504 b on one side of the holder502 are angled to reflect the configuration of the block 510. Thisshifts the passageway 506 on the side of the shell 504 b so that it ispositioned to receive dust that rides up on the angled surface of thesanding block 510. Apertures 508 are located on the side of the secondshell 504 b to allow air/dust to be drawn from around the resilientsanding block 510 into the passageway 506 and eventually out of thesanding system 500 via the vacuum attachment 538.

FIGS. 19, 20 and 21 show an alternative embodiment of a sanding system600. This system is similar to the previously described system of FIGS.16-18 in that it comprises a holder 602 having a first shell 604 a and asecond shell 604 b. A passageway 606 is formed between the first shell604 a and the second shell 604 b that allows for air/dust to be drawn infrom around the periphery of the resilient sanding block 610 anddirected to a dust collection receptacle (not shown) via a vacuumattachment tube 638. The side walls of the first shell 604 a mayfrictionally retain the resilient sanding block 610 whose dimensions maybe slightly larger than the interior dimensions of the shell. Apassageway 606 is formed between the first and second shells 604 a, 604b to facilitate air flow from around the periphery of the resilientsanding block 610 into the passageway 606 and then into the vacuumattachment tube 638 and onto a collection receptacle (not shown).Preferably, the shells 604 a-b are connected to one another with spacersor ribs 650 that are positioned at intervals to provide for air to flowbetween the shells 604 a-b.

Note that the holder 602 in FIGS. 19-21 does not have the same type ofhandle as in the previous embodiment. Rather, with this embodiment, theholder 602 further functions as a handle that can be gripped by a user.As will be understood, the particular shape of the holder/handle 602need not be limited to the particular shape depicted. For example, thehandle portion 642 may extend vertically, relative to the longitudinalaxis of the sanding block 610.

FIG. 22 illustrates an alternate embodiment of a sanding system 700,comprising a holder 702 and a resilient block 710. The holder 702 issimilar to the holder depicted in FIGS. 6 and 7 in that it has aplurality of side walls that are connected to each other by a top wall.One of the side walls of the holder 702 has an exit port 740. As withthe holder of FIGS. 6-7, the holder 702 of this embodiment includes anupper chamber or passageway 706 that is in communication with the exitport 740. This embodiment differs from the embodiment of FIGS. 6-7 inthat it is configured to be used with resilient blocks 710 having aplurality of apertures or through holes 780. The holder 702 alsocomprises a skirt 704 (shown in phantom) that frictionally retains theresilient sanding block 710.

The resilient sanding block 710 of this embodiment also has hookmaterial 782 disposed on a first major surface 724 of the block 710. Thehook material 782 may be attached to the surface 724 by laminating asheet of hook material 782 via adhesive to the first major surface 724or any other portion of the resilient sanding block 710 in where hookmaterial is desired. The hook material 782 corresponds to a loopmaterial 784 that is attached to an abrasive sheet 760. The abrasivesheet 760 is thereby removably attached to the resilient sanding block710. The abrasive sheet 760 may be a sanding screen and could be made ofa plastic material having the characteristics of a grater. If a sandingscreen is used, the sanding screen will preferably have a grit size fromabout 40 to about 400 grit. The resilient sanding block 710 can befrictionally maintained by a skirt 704 formed by the holder 702.

Inside the holder 702 are support ribs or spacers 750 that serve toposition the resilient block 710 away from the passageway 706 so that itpartially closes the walls of the holder 702 creating a substantiallyenclosed passageway 706. Each spacer 750 has an aperture 708 or slot 709to allow air/dust to therebetween. In operation with an vacuum source,air and or dust will travel from through the abrasive sheet 760, throughapertures 780 in the resilient sanding block 710, into the holder 702and then out of the sanding device 700 through the exit port 740.

FIGS. 23-24 depicts a profile view of a machine 800 designed for formingchannels in a resilient sanding block 810. The principle components ofthe machine 800 are a series of six saw blades 802 a-f, a chain conveyorsystem 804, a machine frame 806, a hopper 808, and a slide plate 812. Aplurality of resilient sanding blocks 810 are automatically fed into themachine 800 by means of a conveyor system 804 and through a series ofsaw blades 802 a-f, three on top and three on bottom, which cut channelsinto both sides of the resilient sanding block 810 in a singleoperation.

The conveyor portion 804 of the machine 800 comprises four sprockets818, two chains 820, and individual catches or tines 816. The chainconveyor system 804 revolves in a clockwise motion around the sprockets818 so that the catches or tines 816 are able to grab individualresilient sanding blocks 810 from a plurality of blocks 810 stacked inthe hopper 808. The resilient sanding blocks 810 fall due to gravityonto the chain conveyor system 804 in-between the tines 816. The chainconveyor system 804 rides on two rails 832 positioned under the slideplate 812. The slide plate 812 has three slots 824 cut into it so thatthe saw blades 802 a-f may extend through the slots 824 and above thesurface of the slide plate 812, thereby allowing the saw blades 802 a-fto form channels in the surface of the resilient sanding blocks 810. Theslide plate 812 also has two longitudinal slots 824, 826 that cut intothe length of the resilient sanding block 810 so that the tines orcatches 816 of the chain conveyor system 804 extend above the surface ofthe slide plate 810 so as to allow the tines 816 to catch or grabresilient sanding blocks 810 from the hopper 808 and push them throughthe saw blades 802 a-f. The chain 820, moving clockwise, transports orpushes the resilient sanding blocks 810 through the saw blades 802 a-f.The saw blades 802 a-f are set up with a series of three blades on topand three blades on the bottom. The top blades 802 a-c turn clockwiseand the bottom blades 802 d-f turn counter-clockwise. As the resilientsanding blocks 810 are fed into the saw blades 802 a-f, a spring bar 814applies pressure to the top of the resilient sanding block 810 pushingit down onto the slide plate 812 so as to provide enough pressure so theresilient sanding block 810 does not kick up while going through the sawblades 802 a-f. Adjustable side guides 822 serve to align the resilientsanding blocks 810 accurately through the saw blades 802 a-f preventingthem from wandering from side to side. In the preferred method, theresilient sanding blocks 810 are stacked into the hopper 808 inquantities of about 40 or 50 at a time and gravity fed onto the conveyor804 and as the conveyor 804 turns the bottom most resilient sandingblock 810 is pulled from the bottom of the stack of blocks 810 by thetines 816, which catch the block 810 and push it along and through thesaw blades 802 a-f. The next resilient sanding block 810 falls onto thechain conveyor system 804 on so on. After the resilient sanding blocks810 are pushed through the saw blades 802 a-f they will have a series ofthree saw kerfs or channels (See FIG. 3) cut in one direction on bothsides of the resilient sanding block 810.

The set of intersecting channels are cut into the resilient sandingblock 810 by the same machine 800 by adjusting the saw blades 802 a-f,the hopper 808 size and the side guides 822 accordingly and by turningthe blocks 810 approximately 90 degrees and restacking them in thehopper 808. Alternatively, the channels may be molded, incised, or heatformed in the resilient sanding block 810.

It is envisioned that, it may be more efficient to have a separatemachine of the same type as the machine 800 set up to cut theintersecting channels so the resilient sanding blocks 810 may be placedin hopper 808 of the second machine 800 after going through the firstmachine 800 without requiring any readjustments. It may also be possibleto set up the two machines 800 (only one is shown) so that the chainconveyor system 804 automatically feeds the resilient sanding blocksonto the conveyor system of the second machine without the need to placethe resilient sanding blocks 810 in the hopper of the second machine(not shown). It may be necessary to install a cooling system (not shown)to run water on the saw blades 802 a-f so that they do not overheat fromcutting the abrasive material on the resilient sanding blocks 810. In athird operation, the resilient sanding blocks 810 would be taken to apunch machine (not shown) with single or multiple hole punches so thatthe aperture 80 or apertures (See FIGS. 1 and 4, for example) may bepunched into the resilient sanding block by means of existing hole punchmechanisms or machines.

FIG. 25 shows a top view of the machine 800 in FIGS. 23-24 illustratingthe principle components of the machine 800 including three saw blades802 d-f located underneath the slide plate 812. The blades arepositioned on a rotatable shaft 828. The slide plate 812 has threerectangular slots 824 that allow the saw blades 802 d-f to extend upthrough the surface of the slide plate 812. The slide plate 812 has twolongitudinal slots 826 that allow the tines or catches 816 to extendabove the surface of the slide plate 812 so that the tines 816 may grabthe individual resilient sanding blocks 810 and push them through thesaw blades 82 d-f. The side guides 822 align and guide the resilientsanding blocks 810 through the saw blades 802 d-f accurately and preventside to side movement of the resilient sanding blocks 810. A pulley 830is attached to the shaft 828 to provide a means of driving the sawblades 802 d-f by motor and belt (not shown). FIG. 25 does not depictthe three saw blades 802 a-c located above the slide table 812 as shownin FIG. 23 for ease in depicting the principle components of the machine800.

Although the preferred embodiments and methods of the present inventionhave been described herein, the above description is merelyillustrative. Further modification of the invention herein disclosedwill occur to those skilled in the respective arts and all suchmodifications are deemed to be within the scope of the invention asdefined by the appended claims.

1-36. (canceled)
 37. A sanding system comprising: a sanding block havinga flexible resilient core, a plurality of exterior surfaces, includingan abrasive first major surface and a second major surface and sidesurfaces and abrasive material coated onto at least the abrasive firstmajor surface; apertures that extend from the abrasive first majorsurface to the second major surface, wherein the flexible resilient coreis configured and arranged to be operatively connected to a suctiondevice; and a holder configured and arranged to hold the flexibleresilient core, the holder being configured and arranged to beoperatively connected to a suction device.
 38. The system of claim 37,further comprising a flexible hose that operatively connects the suctiondevice to the flexible resilient core.
 39. The system of claim 37,further comprising a dust collection receptacle operatively connected tothe suction device.
 40. The system of claim 37, further comprising ahandle, the handle attached to the holder.
 41. The system of claim 37,wherein the holder comprises a grip.
 42. The system of claim 37, whereinsaid sanding block further comprises apertures that are generallycircular.
 43. The system of claim 37, wherein said sanding block furthercomprises a flexible core that is generally rectangular and has athickness defined by the first and second major surfaces.
 44. The systemof claim 37, wherein said sanding block comprises first and second majorsurfaces that are generally parallel with respect to each other.
 45. Thesystem of claim 37 wherein the flexible resilient core comprisesresilient foam material.
 46. The system of claim 37, wherein said holderfurther comprises an upper chamber having spacers positioned within saidupper chamber, wherein said spacers position the sanding block away fromsaid chamber, and a skirt that frictionally retains said sanding blockwithin the holder.
 47. An improved sanding block comprising: oneflexible resilient core having a plurality of exterior surfaces,including one abrasive first major surface and one second major surfaceand side surfaces and abrasive material coated onto at least the oneabrasive first major surface; and apertures that extend from the oneabrasive first major surface to the one second major surface.
 48. Theimproved sanding block of claim 47, further comprising apertures thatare generally circular.
 49. The improved sanding block of claim 47,further comprising the one resilient flexible core that is generallyrectangular and has a thickness defined by the one abrasive first majorsurface and the one second major surface.
 50. The improved sanding blockof claim 47 further comprising the one abrasive first major surface andthe one second major surface being generally parallel with respect toeach other.
 51. The improved sanding block of claim 47, furthercomprising the one abrasive first major surface and the one second majorsurface being generally flat.
 52. The improved sanding block of claim47, wherein the one flexible resilient core comprises resilient foammaterial.
 53. The improved sanding block of claim 47, wherein the oneabrasive first major surface and the one second major surface areabrasive surfaces.
 54. The improved sanding block of claim 47, havinghook and loop fastening material attached to the one second majorsurface.
 55. A method of forming a sanding block, comprising: providinga flexible resilient core having a plurality of exterior surfaces,including an abrasive first major surface and a second major surface andside surfaces; coating abrasive material onto at least the abrasivefirst major surface; and extending apertures from the abrasive firstmajor surface to the second major surface.
 56. The method of claim 55,further comprising providing a resilient flexible core is generallyrectangular and has a thickness defined by the first and second majorsurfaces.